Absorbent article with tension-dividing side panels

ABSTRACT

Absorbent articles such as disposable diapers, incontinent briefs, diaper holders, training pants, and the like, that provide dynamic fit about the wearer by the use of extensible, outwardly extending side panels. The side panel includes at least one discontinuity for dividing the tensile force extending the side panel into a waist-directing force and a leg-directing force. The waist-directing force is transmitted by the side panel to the waist area of the article to maintain the waist area in a snug, but comfortable, fit against the waist of the wearer. The leg-directing force is transmitted by the side panel to the leg cuff area of the article to prevent leakage between the leg cuff and the wearer&#39;s leg.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. application Ser.No. 09/773,241 filed Jan. 31, 2001.

FIELD OF THE INVENTION

The present invention relates to absorbent articles that are worn, suchas diapers, incontinent briefs, diaper holders, training pants, sanitarynapkins, and the like. More particularly the present invention relatesto absorbent articles having side panels having at least onediscontinuity for reducing or changing the transmission of tensileforces within the side panel in order to distribute the tensile forcesto the waist area of the article and to the leg cuff area of the articleto provide improved fit of the article and improved comfort for thewearer.

BACKGROUND OF THE INVENTION

Infants and other incontinent individuals wear absorbent articles suchas diapers and incontinent briefs to receive and contain dischargedurine and other body exudates. Such absorbent articles function both tocontain the discharged materials and to isolate those materials from thebody of the wearer and from the wearer's articles and bed clothing.Disposable absorbent articles having many different basic designs areknown in the art. For example, U.S. Reissue Pat. No. Re. 26,152,entitled “Disposable Diaper,” which issued on Jan. 31, 1967, to Duncanet al., describes a basic disposable diaper structure that has achievedwide acceptance and considerable commercial success. Additionally, U.S.Pat. No. 5,151,092, entitled “Absorbent Article With Dynamic ElasticWaist Feature Having a Predisposed Resilient Flexural Hinge,” whichissued on Sep. 29, 1992, to Buell et al., describes an absorbent articlehaving an elastic waist feature for improving dynamic fit as well asimproving containment characteristics, and U.S. Pat. No. 4,857,067,entitled “Disposable Diaper Having Shirred Ears,” which issued on Aug.15, 1989, to Wood, et al., describes a disposable diaper with elasticside panels that are intended to overlie the hips of the wearer. Thoseelastic structural elements are intended to permit expansion andcontraction of the article in response to the wearer's motions and tomaintain the fit of the absorbent article about the wearer during use.

A number of improvements to the basic Duncan et al. structure have beendeveloped over the years. Some of those improvements have been directedto providing a better fit of the article on the body of the wearer andto reducing the likelihood of leakage of discharged materials betweenthe absorbent article and the legs of the wearer. Accordingly, suchabsorbent articles have been provided with elastic leg openings, elasticwaist elements, and elasticized side panels for improved fit. In thatregard, one such improvement that has also achieved wide acceptance andsubstantial commercial success is an elasticized leg cuff structure thatis disclosed in U.S. Pat. No. 3,860,003, entitled “Contractable SidePortions For Disposable Diaper”, which issued on Jan. 14, 1975, toBuell.

Although several structural modifications and other changes forimproving the fit and for reducing the incidence of leakage with sucharticles have been developed, those problems have not been fully solved.For example, it has been found that absorbent articles having elasticclosures still often have a tendency to gap away from the body of thewearer during use. Those continuing problems have been found to becaused largely by the motions of the wearer during use of the article.Thus, as the wearer changes position, there can be significantdimensional changes in the wearer's waist, stomach, hips, buttocks, andlegs. Such dimensional changes are particularly noticeable in infants.The circumference of the infant from hip to hip through the buttocks ismuch bigger than through the front waist and stomach area. Thus, as thewearer moves, the articles often are unable to expand and contract inproportion to the circumference of the wearer in the hips through thebuttocks, caused primarily by their construction using materials thatare relatively unaccomodating to such body changes by virtue of beingmade from relatively inelastic materials. Thus, the article tends tosag, to gap, and to slip to a degree that fit is degraded and thelikelihood of leakage is increased. Further, because the article oftencannot expand sufficiently to accommodate wide ranges of dimensionalchanges, the result is pressure that is applied to the body that cancause skin marking and wearer discomfort.

Thus, it would be advantageous to provide an absorbent article havingelastic features that provide better fit. It would also be desirable toprovide an absorbent article having improved dynamic fit relative to thebody of the wearer, particularly in the waist and high areas. Further,it would be desirable to provide an absorbent article having a structurethat more closely adapts to the dimensional changes in the wearer's bodyresulting from wearer movements. It would also be advantageous toprovide an absorbent article with side panels with a structure thatreduces or changes the tensile forces within the side panel to improvethe fit of the article.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, there isprovided an absorbent article that is worn about the waist and lowertorso. The article is configured to be worn over and about the lowertorso of a wearer. The article includes a containment assembly having afirst longitudinal edge and a second longitudinal edge opposed thereof.The article further includes a first end edge and a second end edgeopposed thereof. The first and the second longitudinal edges areconfigured to contact the legs of the wearer, and the first and thesecond end edges are configured to contact the waist of the wearer. Theabsorbent article further includes at least one side panel carried bythe containment assembly and extending outwardly from the firstlongitudinal edge of the containment assembly adjacent the first endedge of the containment assembly. The side panel includes an innerregion having at least one discontinuity for dividing a tensile forceapplied to the side panel into a waist-directing force and aleg-directing force. The side panel further includes a waist region anda leg region separated thereof by the at least one discontinuity. Thewaist region is configured to transmit the waist-directing force, andthe leg region is configured to transmit the leg-directing force.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of one embodiment of the absorbent article of thepresent invention in the form of a disposable diaper having portions ofthe structure cut away to reveal underlying structure.

FIG. 2 is a perspective view of one embodiment of the absorbent articleof the present invention in its assembled form when worn.

FIG. 3 is a diagrammatic view showing the tensile force vectors in aside panel of the absorbent article of the present invention of FIGS. 1and 2.

FIG. 4 is another diagrammatic view showing a side panel of the presentinvention that includes extensibility patterns.

FIG. 5 is another diagrammatic view of a side panel of the presentinvention having one form of interiorly-positioned opening.

FIG. 6 is an alternative embodiment of the present invention showing aside panel with a differently-shaped interiorly-positioned opening.

FIG. 7 is another embodiment of the present invention showing a sidepanel having a single, interiorly-positioned rectilinear slit.

FIG. 8 is an alternative embodiment of a present invention showing aside panel having a plurality of interiorly-positioned, separatedrectilinear slits.

FIG. 9 is another embodiment of the present invention showing a sidepanel having a plurality of interiorly-positioned curvilinear slits.

FIG. 10 is a force diagram showing the division of forces provided by aside panel in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “absorbent article” refers to articles that areworn and that absorb and contain body exudates. More specifically, itrefers to articles that are placed against or in close proximity to thebody of the wearer to absorb and contain the various exudates dischargedfrom the body.

The term “disposable” is used herein to describe absorbent articles thatare not intended to be laundered or otherwise restored or reused as anabsorbent article (i.e., they are intended to be discarded after asingle use and, preferably, to be recycled, composted or otherwisedisposed of in an environmentally compatible manner).

The term “unitary” as applied to an “absorbent article” refers toabsorbent articles formed of separate parts that are joined together toform a coordinated entity so that they do not require separatemanipulative parts like a separate holder and liner. One embodiment of aunitary absorbent article in accordance with the present invention isthe disposable diaper 20 shown in FIG. 1.

As used herein, the term “diaper” refers to an absorbent article of thetype generally worn by infants and other incontinent persons, and thatis worn about the lower torso of the wearer. It should be understood,however, that the present invention is also applicable to other forms ofabsorbent articles, such as incontinent briefs, incontinentundergarments, diaper holders and liners, feminine hygiene garments,training pants, and the like.

FIG. 1 is a plan view of a diaper 20 in accordance with the presentinvention. Diaper 20 includes several elasticized portions, some ofwhich are normally in at least a partially contracted state so that partof the diaper includes gathered areas. As shown in FIG. 1, however,diaper 20 is in its flat-out, uncontracted state in which elasticizedportions that are normally in at least partially contracted form andinclude some gathers when the diaper is in its initial condition, beforeit is applied to a wearer, have been stretched so that anyelastic-induced initial contractions or gathers are overcome so that thediaper is shown in substantially completely flat condition. Elasticizedportions that are normally in uncontracted, relaxed form before use,such as the side panels, are left in their uncontracted condition. Asdiaper 20 is illustrated in FIG. 1, outer surface 52, the portion of thediaper that faces away from the wearer when the diaper is worn, isfacing the viewer of that drawing Figure. Additionally, portions ofouter surface 52 of diaper 20 have been cut away to more clearly showthe interior construction of the diaper.

As shown in FIG. 1, diaper 20 has containment assembly 22 that includesinner surface 54 that faces the body of the wearer when the diaper isworn. Preferably inner surface 54 is defined by liquid pervious topsheet24. Diaper 20 also includes liquid impervious backsheet 26 that definesouter surface 52 and that is joined with topsheet 24 about theirrespective marginal edges, and absorbent core 28 positioned betweentopsheet 24 and backsheet 26. Additionally, for improved fit on the bodyof a wearer, diaper 20 also preferably includes elasticized leg cuffs32, elasticized waist area 34, and side panels 73. Fastening elementsdefining fastening arrangement 36 are provided to secure the diaper inposition on the body of the wearer.

Diaper 20 also includes front region 56, back region 58, and periphery60 that are defined by the joined outer edges of each of topsheet 24 andbacksheet 26. The longitudinal edges of the diaper 20 are designated 62and the end edges are designated 64. Inner surface 54 of diaper 20includes that portion of the diaper that is positioned adjacent to thewearer's body during use (i.e., inner surface 54 generally is formed byat least a portion of topsheet 24 and other components that can bejoined to topsheet 24). Outer surface 52 of diaper 20 includes thatportion of the diaper that is positioned away from the wearer's body(i.e., outer surface 52 generally is formed by at least a portion ofbacksheet 26 and other components that can be joined to backsheet 26).As used herein, the term “joined” includes directly securing one elementto another element by affixing the elements directly to each other,either fully or partially, and it also includes indirectly securing oneelement to another element by affixing one element to one or moreintermediate members that, in turn, can be affixed to the other element.

Front region 56 and back region 58 each extend from respective end edges64 of diaper 20 inwardly to lateral centerline 66. Front region 56includes central region 68 and a pair of end regions 70. Back region 58includes central region 68 and a pair of end regions 72 that includelaterally-outwardly-extending side panels 73. Although it is notessential that the side panels 73 be identical, they preferably aremirror images one of the other.

Containment assembly 22 of diaper 20 as shown in FIG. 1 defines the mainbody (chassis) of diaper 20 and is constructed to receive and retain thebody exudates of the wearer. Containment assembly 22 includes at leastabsorbent core 28 and preferably outer covering layers, includingtopsheet 24 and backsheet 26, that enclose absorbent core 28. When theabsorbent article includes both an exudate retainer and a separateliner, the containment assembly 22 generally includes the exudateretainer and the liner (i.e., containment assembly 22 includes one ormore layers of material to define the exudate retainer, while the linerincludes the topsheet and the backsheet.) For unitary absorbentarticles, containment assembly 22 includes the main structure of thediaper with additional structural and functional elements added to formthe composite diaper structure. Thus, containment assembly 22 for diaper20 generally includes topsheet 24, backsheet 26, and absorbent core 28.

Topsheet 24 and backsheet 26 have length and width dimensions generallylarger than those of absorbent core 28 and extend beyond the edges ofabsorbent core 28 to define periphery 60 of diaper 20. Although topsheet24, backsheet 26, and absorbent core 28 can be assembled in a variety ofwell-known configurations, preferred diaper configurations are describedgenerally in U.S. Pat. No. 3,860,003, entitled “Contractible SidePortions for Disposable Diaper,” which issued on Jan. 14, 1975, toKenneth B. Buell, and in U.S. Pat. No. 5,151,092, entitled “AbsorbentArticle With Dynamic Elastic Waist Feature Having A PredisposedResilient Flexural Hinge,” which issued on Sep. 29, 1992, to Kenneth B.Buell et al, the disclosure of each of the patents is herebyincorporated herein by reference.

Absorbent core 28 may comprise any absorbent material which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. Absorbent core 28 may be manufactured in a widevariety of sizes and shapes (e.g., rectangular, hourglass, “T”-shaped,asymmetric, etc.) and may comprise a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles, such as comminuted wood pulp, which is generally referred toas airfelt. Examples of other suitable absorbent materials includecreped cellulose wadding; meltblown polymers, including coform;chemically stiffened, modified or cross-linked cellulosic fibers;tissue, including tissue wraps and tissue laminates; absorbent foams;absorbent sponges; superabsorbent polymers; absorbent gelling materials;or any other known absorbent material or combinations of materials.

Backsheet 26, or any portion thereof, may be elastically extensible inone or more directions. In one embodiment, backsheet 26 may comprise astructural-elastic-like-film (“SELF”) web. A SELF web is an extensiblematerial that exhibits elastic-like behavior in the direction ofelongation without the use of added elastic materials, and is describedin more detail in U.S. Pat. No. 5,518,801 entitled “Web MaterialsExhibiting Elastic-Like Behavior” issued to Chappell, et al. on May 21,1996, and which is incorporated herein by reference. In alternateembodiments, the backsheet 26 may comprise elastomeric films, foams,strands, or combinations of these or other suitable materials withnonwovens or synthetic films.

Topsheet 24 is preferably compliant, soft-feeling, and non-irritating tothe wearer's skin. Topsheet 24 may comprise one or more apertures toease penetration of exudates therethrough, such as urine and/or feces(solid, semi-solid, or liquid). The size of at least the primaryaperture is important in achieving the desired waste encapsulationperformance. If the primary aperture is too small, the waste may notpass through the aperture, either due to poor alignment of the wastesource and the aperture location or due to fecal masses having adiameter greater than the aperture. If the aperture is too large, thearea of skin that may be contaminated by “rewet” from the article isincreased. Typically, the aperture should have an area of between about10 cm² and about 50 cm². The aperture preferably has an area of betweenabout 15 cm² and 35 cm².

Diaper 20 preferably further includes leg cuffs 32 which provideimproved containment of liquids and other body exudates. Leg cuffs 32may also be referred to as leg bands, side flaps, barrier cuffs, orelastic cuffs. U.S. Pat. No. 3,860,003 describes a disposable diaperwhich provides a contractible leg opening having a side flap and one ormore elastic members to provide an elasticized leg cuff (a gasketingcuff). U.S. Pat. Nos. 4,808,178 and 4,909,803 issued to Aziz et al. onFeb. 28, 1989 and Mar. 20, 1990, respectively, describe disposablediapers having “stand-up” elasticized flaps (barrier cuffs) whichimprove the containment of the leg regions. U.S. Pat. Nos. 4,695,278 and4,795,454 issued to Lawson on Sep. 22, 1987 and to Dragoo on Jan. 3,1989, respectively, describe disposable diapers having dual cuffs,including gasketing cuffs and barrier cuffs. In some embodiments, it maybe desirable to treat all or a portion of leg cuffs 32 with a lotion, asdescribed above. The disclosures of each of those patents are herebyincorporated by reference.

Although each leg cuff 32 can, if desired, be configured to be similarto any of the leg bands, side flaps, barrier cuffs, or elastic cuffsdescribed in the patents identified above, it is preferred that each legcuff 32 includes gasketing cuff 103 and barrier cuff 84, such as thatdescribed in the above-identified U.S. Pat. Nos. 4,695,278 and4,795,454. As shown in FIG. 1, gasketing cuff 103 includes a portion oftopsheet 24, a portion of backsheet 26, and a plurality of elasticmembers 104 positioned therebetween, while barrier 84 includes a barrierflap 85 and one or more spacing elastic members 86.

The diaper 20 preferably further includes elastic waist feature 34 thatprovides improved fit and containment. Elastic waist feature 34 is thatportion or zone of the diaper 20 that is intended to elastically expandand contract to dynamically fit the wearer's waist. Elastic waistfeature 34 at least extends longitudinally outwardly from at least oneof waist edges 83 of absorbent core 28 and generally forms at least aportion of end edge 64 of diaper 20. Disposable diapers are generallyconstructed so as to have two elastic waist features, one positioned inthe front region and one positioned in the back region, although diaperscan instead be constructed with a single elastic waist feature. Further,while the elastic waist feature or any of its constituent elements caninclude a separate element affixed to the diaper, elastic waist feature34 is preferably constructed as an extension of other elements of thediaper 20, such as backsheet 26 or topsheet 24, preferably bothbacksheet 26 and topsheet 24. As shown in FIG. 1, elastic waist feature34 includes elasticized waistband 35 that at least includes elasticwaist member 76, which may include a crosslinked natural rubber foam,operatively associated between topsheet 24 and backsheet 26. Elasticwaist feature 34 may be constructed in a number of differentconfigurations including those described in U.S. Pat. No. 4,515,595issued to Kievit et al. on May 7, 1985; U.S. Pat. No. 4,710,189 issuedto Lash on Dec. 1, 1987; U.S. Pat. No. 5,151,092 issued to Buell on Sep.9, 1992; and U.S. Pat. No. 5,221,274 issued to Buell on Jun. 22, 1993.Other suitable waist configurations may include waistcap features suchas those described in U.S. Pat. No. 5,026,364 issued to Robertson onJun. 25, 1991 and U.S. Pat. No. 4,816,025 issued to Foreman on Mar. 28,1989. The disclosure of each of those references is hereby incorporatedherein by reference.

The diaper 20 may also include a fastening system 36. The fasteningsystem 36 preferably maintains the front region 56 and the back region58 in a configuration so as to provide lateral tensions about thecircumference of the diaper 20 to hold the diaper 20 on the wearer. Thefastening system 36 preferably comprises a surface fastener such as tapetabs 92, hook and loop fastening components and/or hermaphroditicfastening components, although any other known fastening means aregenerally acceptable. Some exemplary surface fastening systems aredisclosed in U.S. Pat. No. 3,848,594 entitled “Tape Fastening System forDisposable Diaper” issued to Buell on Nov. 19, 1974; U.S. Pat. No. B14,662,875 entitled “Absorbent Article” issued to Hirotsu et al. on May5, 1987; U.S. Pat. No. 4,846,815 entitled “Disposable Diaper Having AnImproved Fastening Device” issued to Scripps on Jul. 11, 1989; U.S. Pat.No. 4,894,060 entitled “Disposable Diaper With Improved Hook FastenerPortion” issued to Nestegard on Jan. 16, 1990; U.S. Pat. No. 4,946,527entitled “Pressure-Sensitive Adhesive Fastener And Method of MakingSame” issued to Battrell on Aug. 7, 1990; the herein before referencedU.S. Pat. No. 5,151,092 issued to Buell on Sep. 9, 1992; and U.S. Pat.No. 5,221,274 issued to Buell on Jun. 22, 1993. An exemplaryinterlocking fastening system is disclosed in co-pending U.S.application Ser. No. 09/143,184 entitled “Absorbent Article FasteningDevice” in the names of Kline et al. filed on Aug. 8, 1998. Thefastening system 36 may also provide a means for holding the article ina disposal configuration as disclosed in U.S. Pat. No. 4,963,140 issuedto Robertson et al. on Oct. 16, 1990. The fastening system may alsoinclude primary and secondary fastening systems, as disclosed in U.S.Pat. No. 4,699,622 entitled “Disposable Diaper Having An Improved SideClosure” issued to Toussant et al. on Oct. 13, 1987 to reduce shiftingof overlapped portions or to improve fit as disclosed in U.S. Pat. No.5,242,436 entitled “Absorbent Article With Fastening System ProvidingDynamic Elasticized Waistband Fit” issued to Weil et al. on Sep. 7,1993; U.S. Pat. No. 5,499,978 entitled “Absorbent Article With DynamicElastic Waist Feature Having A Predisposed Resilient Flexural Hinge”issued to Buell et al. on Mar. 19, 1996; U.S. Pat. No. 5,507,736entitled “Absorbent Article With Dynamic Elastic Waist FeatureComprising An Expansive Tummy Panel” issued to Clear et al. on Apr. 16,1996; U.S. Pat. No. 5,591,152 entitled “Absorbent Article With DynamicElastic Waist Feature Having A Predisposed Resilient Flexural Hinge”issued to Buell et al. on Jan. 7, 1997. Each of these patents and theco-pending application are incorporated herein by reference. Inalternative embodiments, opposing sides of the article may be seamed orwelded to form a pant. This allows the article to be used as a pull-ontype diaper, such as a training pant.

Diaper 20 may also includes at least one, but preferably two side panels73 positioned preferably in back region 58 for connecting waist features34 of diaper 20 around the wearer. Alternatively, if desired, the sidepanel 73 can instead be positioned in the front of the wearer, adjacentthe stomach of the wearer, if desired.

Side panel 73 can be secured to the containment assembly 22 by anysuitable method, including by a suitable adhesive, by heat sealing, byultrasonic sealing, by pressure bonding, or combinations thereof. Inthat regard, the proximal region 214 of the side panel 73 can be securedto topsheet 24, or to backsheet 26, or to any layer of material disposedbetween backsheet 24 and topsheet 26, if desired. Alternatively, ifdesired, side panel 73 can be integrally formed with topsheet 24 and/orbacksheet 26 or any one or more layers of materials joined to topsheet24 and/or backsheet 26.

Side panels 73 can take on a number of different sizes, shapes,configurations and materials. The exact length, width, and thickness ofside panel 73 can vary depending on the dimensions of the intended userand the exact configuration of side panel 73. Examples of the size ofsuitable side panels 73 to be part of a diaper 20 worn by a medium sizedinfant are that they be generally trapezoidal in shape, havingdimensions between about 2 and 4 inches in the longitudinal direction ofdiaper 20 and between about 2 and 5 inches in the lateral direction ofdiaper 20. It should be noted that although shown as defined bysubstantially straight lines, each of the peripheral edges of side panel73 can be defined by curved lines, if desired, or by a combination ofstraight and curved lines.

Each of side panels 73 can be formed from any suitable extensible,stretchable, or elastomeric material. (As used herein, the term“extensible” refers to materials that can increase in at least onedimension. The term “stretchable” refers to materials that areextensible when stretching forces are applied to the material, and offersome resistance to extension. The term “elastomeric” refers to materialsthat extend in at least one direction when a force is applied and returnto approximately their original dimensions after the force is released.)The extensible, stretchable, or elastomeric material can include asingle layer material or a laminate of two or more layers of materialsthat have been joined together. One material that has been found to beespecially suitable for use in side panels 73 is a laminate of twocoverstock layers with an elastomeric film sandwiched between thecoverstock layers. As used herein “coverstock” can include any woven ornonwoven materials. An example of a suitable coverstock material is anonwoven material manufactured by Veratec, Inc., a Division of theInternational Paper Company, of Walpole, Mass., designated P-8. Anexample of a suitable film to be sandwiched between coverstock layers isthe elastomeric film EXX-500, (formerly EXX-7) manufactured by the ExxonChemical Company of Lake Zurich, Ill. Other suitable materials for useas, or in the extensible side panels and side panel members includestructural, elastic-like film (SELF) webs, as described hereinbelow,synthetic or natural rubber, synthetic or natural rubber foams,elastomeric scrims, woven or nonwoven elastomeric webs, elastomericcomposites such as elastomeric nonwoven laminates, zero strain stretchlaminates, prestrained stretch laminates or the like. U.S. Pat. No.5,151,092, entitled “Absorbent Article with Dynamic Elastic WaistFeature Having a Predisposed Resilient Flexural Hinge,” which issued onSep. 29, 1992, to Buell et al., describes suitable zero stain stretchlaminates and prestrained stretch laminates, and the disclosure of thatpatent is hereby incorporated herein by reference to the same extent asif fully rewritten.

One preferred mechanical operation suitable for providing stretchcharacteristics in a material to be used for the side panels isdescribed hereinabove with respect to imparting elasticity to backsheet24. As described hereinabove, structural elastic-like film (SELF) web isan extensible material that exhibits an elastic-like behavior in thedirection of elongation without the use of added elastic materials.Methods and apparatus for forming such SELF webs are disclosed in U.S.Pat. No. 5,156,793, entitled, “Method for Incrementally Stretching ZeroStrain Stretch Laminate Sheet in a Non-Uniform Manner to Impart aVarying Degree of Elasticity Thereto,” which issued on Oct. 20, 1992, toKenneth B. Buell et al.; in U.S. Pat. No. 5,167,897, entitled, “Methodfor Incrementally Stretching a Zero Strain Stretch Laminate Sheet toImpart Elasticity Thereto, “which issued on Dec. 1, 1992, to Gerald M.Weber et al.; and in U.S. Pat. No. 5,518,801, entitled, “Sheet MaterialsExhibiting Elastic-Like Behavior,” which issued on May 21, 1996, toCharles W. Chappell et al., the disclosures of each of the patents ishereby incorporated herein by reference to the same extent as if fullyrewritten.

The strainable web material can be used in various different forms inextensible side panels 73 of diaper 20. One example of a suitable formof structural elastic-like film is a laminate. The laminate includes astrainable web material secured between two longitudinally extensible,preferably carded, nonwoven webs. (In addition, the strainable webmaterial can also be used in the various other components of theabsorbent article described herein.)

Alternatively, side panels 73 can be made from extensible materialshaving areas of different elastic behavior achieved by means other thanthe aforementioned mechanical operations, such as slitting or cuttingthe extensible material that forms the side panels 73. In suchembodiments, the slits or cuts in the material are not limited to anyparticular sizes or shapes. For example, the material making up the sidepanels 73 can be fully or partially severed or can have portions cut outor bonded to create different extensibility characteristics in the sidepanels.

As used herein, the term “fully severed” refers to single component sidepanels having a cut or slit running the entire distance between theproximal edge to the distal edge of the extensible side panel. The term“partially severed” refers to single component side panels having a cutor slit that does not extend from the proximal edge to the distal edgeof the side panels.

FIG. 2 illustrates diaper 20 in its assembled form, after application ofdiaper 20 to the body of a wearer. Diaper 20 may be applied to a wearerby positioning back region 58 under the wearer's lower back and bydrawing the remainder of the diaper between the wearer's legs so thatfront region 56 is positioned over the abdomen of the wearer. The tabportions of tabs 92 are then released to expose the adhesive, and theperson applying the diaper then individually draws each of side panels73 around the waist of the wearer, while still grasping tab 92. Sidepanels 73 will typically be under tension and will be at least partiallyextended during that application operation, to conform diaper 20 withthe size and shape of the wearer. Fastening component of tabs 92 arethen individually attached to effect the side closure of diaper 20 andto secure diaper 20 about the lower torso of the wearer.

Referring to FIGS. 1 and 2 showing one embodiment of the presentinvention, wherein side panel 73 includes cut line 260 which separatesthe force-transmitting capability of side panels 73 into a pair ofdistinct regions, waist region 200 and leg region 202. (Cut line 260 cansevere the side panel material through the side panel material, orpartially, severing any one or more layers of the side panel materialleaving one or more layers uncut. As shown in FIG. 2, the tensionapplied to side panel 73 may cause the edges of cut line 260 to separateto define opening 265.) Waist region 200 and leg region 202 can functionsubstantially independently of each other and can sustain and transmitdifferent levels of tensile forces to different portions of the diaperstructure. Waist regions 200 and leg region 202 extend preferablyoutwardly from diaper 20 at different angles, relative to transversecenterline 66, to meet and connect with each other at an area adjacentto tab 92. Because regions 200 and 202 diverge from each, waist region200 has a different primary direction of extensibility than does legregion 202, which provides side panel 73 with unique, multi-directionalstretch characteristics. Thus, when waist region 200 is placed undertension, by pulling laterally outwardly on tab 92, the tensile forcewithin waist region 200 is transmitted to and acts on elastic waistfeature 34 of diaper 20 to impart a tensile force to elastic waistfeature 34 that serves to maintain tension within the elastic waistfeature 34 to retain diaper 20 in a predetermined position about thewearer's waist. Because both side panels 73 and elastic waist feature 34may be extensible, they each can expand and contract in response to bodydimensional changes resulting from movements of the wearer, and therebyserve to maintain elastic waist feature 34 of diaper 20 in a snug, yetcomfortable, fit against the wearer's body throughout the period of useof the diaper. Thus, diaper 20 is retained in its proper operativeposition on the body of the wearer so that diaper 20 is effective forits intended purpose.

Similarly, when leg region 202 is placed under tension, which alsoresults from pulling laterally outwardly on tab 92, the tensile forcewithin leg region 202 is transmitted to and acts on elasticized cuff 32of diaper 20. As a result, leg cuff 32 is maintained under tension sothat it remains in close contact about the wearer's thigh to preventleakage between the diaper and the wearer's thigh. Because side panel 73and leg cuff 32 each may be extensible, they each can expand andcontract in response to body dimensional changes resulting frommovements of the wearer, and they thereby serve to maintain leg cuff 32in snug, yet comfortable, contact with the wearer's thigh throughout theperiod of use of diaper 20 to prevent leakage between cuff 32 and thewearer's thigh.

Referring to FIG. 3 showing an enlarged view of side panel 73 of FIG. 1,wherein because of the position of cut line 260, waist region 200 has aprimary direction of extensibility G-G that is different from a primarydirection of extensibility H-H of leg region 202, thereby providing sidepanel 73 with unique multi-directional stretch characteristics. Waistregion 200 is that portion or element of side panel 73 designed toinitially provide the tension to secure diaper 20 about the waist of thewearer, and once “activated”, or made extensible, to thereafterdynamically expand and contract with the motions of the wearer tomaintain the waist of the diaper in a snug yet comfortable fitthroughout the period of use. Preferably, waist region 200 is positionedso that first lateral edge 218 is positioned to connect with and to forma part of end edge 64 of diaper 20.

The primary direction of extensibility G-G of waist region 200 includesa first vector component oriented laterally outwardly that is preferablygreater than zero, and a second vector component that is preferablygreater than or equal to zero and is oriented toward lateral centerline66 of diaper 20. More preferably, the first vector component of theprimary direction of extensibility G-G is greater than the second vectorcomponent. (It should be noted, however, that the whole or segments ofthe waist region 200 can also be extensible in directions other than theprimary direction of extensibility G-G.) An angle A in FIG. 3 representsthe angle (measured clockwise or counterclockwise) between the primarydirection of extensibility G-G of waist panel 200 and side panel lateralaxis 206, which is generally parallel to lateral centerline 66. (In FIG.3, angle A is measured in a clockwise direction from lateral axis 206.)Angle A can vary from about 0° to about 45° or from about 5° to about20° or from about 10° to about 15°.

Leg region 202 is that portion or element of side panel 73 intended toexpand and contract with the dynamic motions of the wearer in the outerthigh region, where the diaper encircles the wearer's leg. As shown inFIG. 3, leg region 202 has a second lateral edge 214. Preferably, legregion 202 is disposed adjacent longitudinal edge 62 of diaper 20 andextends laterally outwardly from a location closer to transversecenterline 66 of diaper 20 than does waist region 200. Preferably, whendiaper 20 is fitted to the wearer, second lateral edge 214 forms a partof the diaper 20 that encircles the thigh of the wearer.

The primary direction of extensibility H-H of leg region 202 includes afirst vector component oriented laterally outwardly that is preferablygreater than zero, and a second vector component that is preferablygreater than or equal to zero and is oriented away from the lateralcenterline 66. (The whole or segments of region 202 can also be made tobe extensible in directions other than the primary direction ofextensibility, if desired.) As shown in FIG. 3, angle B represents theangle between the primary direction of extensibility H-H of leg region202 and side panel lateral axis 206. (As used herein, the angle B ismeasured counterclockwise from lateral axis 206.) Angle B can vary fromabout 0 and to 40 degrees or from about 10 to about 35 degrees or fromabout 20 to about 30 degrees. In one preferred embodiment, when diaper20 is initially fitted to the wearer, leg region 202 overlies the outerthigh portion of the wearer's leg. Once made extensible, leg panel 202is capable of expansion and contraction in response to the motions ofthe wearer's legs to maintain a snug fit of leg cuff 32 about the leg ofthe wearer throughout the period of use of the diaper. This improves thecontainment characteristics of the diaper while also reducing thelikelihood of red marks on the wearer's skin from excessive leg cufftension.

Each of regions 200 and 202 can take on a number of different sizes,shapes, configurations and materials. The exact length, width, andthickness of waist region 200 and leg region 202, will vary depending onthe dimensions of the intended user and the exact configuration of sidepanel 73. Accordingly, waist region 200 can be identical in size andshape with leg region 202, or it can have different dimensions, so longas waist region 200 can be operatively associated with leg region 202and containment assembly 22 of diaper 20 to provide themulti-directional stretch characteristics of the invention describedherein.

In one preferred embodiment as shown in FIG. 4, waist region 200preferably has a primary direction of extensibility G-G that issubstantially parallel with first lateral edge 218 of side panel 73.Lines 201 represent the axes of one preferred SELFing pattern in waistregion 200, and are disposed preferably generally perpendicular toprimary direction of extensibility G-G. Leg region 202 preferably has aprimary direction of extensibility H-H at an angle to the lateralcenterline 66 and the longitudinal centerline 67 of diaper 20 and thatis preferably generally parallel with second lateral edge 214 of sidepanel 73. Lines 203 represent the axes of one preferred SELFing patternin leg region 202, and are disposed substantially perpendicular toprimary direction of extensibility H-H. The embodiment of side panel 73shown in FIG. 4 is a single-piece side panel having a distinct boundaryline 261 between the waist region 200 and leg region 202 that defineswhere the elastic characteristics of each region begins and ends.Boundary line 261 is preferably aligned with cut line 260. If desired,boundary line 261 between waist region 200 and leg region 202 can belocated at other positions on side panel 73.

Referring to FIG. 5, there is shown another embodiment of a singlepiece, or unitary, side panel 73 a. As shown, side panel 73 a can haveouter panel 250 and inner panel 252, wherein outer panel 250 has ashorter length, taken in the longitudinal direction of diaper 20, thandoes inner panel 252. In that regard, inner panel 252 can serve as aconnector joined to assembly 22 by a suitable adhesive, by heat sealing,by ultrasonic sealing, by pressure bonding or any combination thereof.Alternatively, side panel 73 a can be integrally formed with backsheet24 and/or with topsheet 26, if desired.

Extending between outer panel 250 and inner panel 252 are waist panel200 a and leg panel 202 a, each of which is disposed preferablyangularly relative to each of outer panel 250 and inner panel 252. Waistpanel 200 a can extend at an angle A relative to lateral axis 206 ofside panel 73 a, and leg panel 202 a can extend at an angle B relativelateral axis 206 of side panel 73 a. In that respect, as noted earlierin connection with FIG. 3, angle A preferably can vary from about 0° toabout 45° or from about 5° to about 20° or from about 10° to about 15°,while angle B can vary from about 0° to about 40° or from about 10° toabout 35° or from about 20° to about 30°. Waist panel 200 a and/or legpanel 202 can have a SELF pattern arranged as shown, for example, inFIG. 4, wherein the individual SELF pattern lines for waist panel 200 aare disposed at an angle relative to the individual SELF pattern linesfor leg panel 202 a.

Side panel 73 a can include an interior open area 254 that is devoid ofmaterial. As shown, open area 254 can also be of generally trapezoidalform, but it can also be of triangular form, if desired, and itpreferably includes stress-relieving corners that can either bechamfer-like, as shown, or, alternatively, they can be concavely curved,or they can be of any other convenient form that reduces the tendencyfor tearing to occur at the corners of open area 254 when side panel 73a is subjected to tensile stresses. Additionally, open area 254 ispreferably positioned relative to the outer edges of side panel 73 a asto define a waist panel 200 a that has a width w that is preferablygreater than the width t of leg panel 202 a. Preferably, the ratio w/tcan vary from about 1:1 to about 4:1 or from about 1.1:1 to about 3:1 orfrom about 1.25:1 to about 2:1, so that the tensile forces within waistpanel 200 a are generally greater than those within leg panel 202 a.Moreover, the widths of each of regions 200 a and 202 a are preferablyuniform along the lengths of the respective regions, as shown in FIG. 5,although the widths can vary or be different along the lengths of therespective regions, if desired.

Inner panel 252 is preferably joined to containment assembly 22 ofdiaper 20, preferably at waist feature 34 that is intended to bepositioned at the back of the wearer when the diaper is worn, althoughit can instead be attached to the waist feature 34 adjacent the stomachof the wearer, if desired. Additionally, if desired, a suitablestiffener element can be attached to inner panel 252 along the innerside edge of the side panel to prevent or limit gathers or puckers inthe side panel material and in the adjoining backsheet material when theside panel is placed under tension, such as while the article is beingapplied to the wearer and also while the article is worn.

Waist panel 200 a preferably has an extensibility which can vary fromabout 5 g/mm to about 50 g/mm or from about 10 g/mm to about 40 g/mm orfrom about 15 g/mm to about 25 g/mm. If the extensibility is too highthe effort required to tension side panel 73 is too large forconvenience, and waist feature 34 of diaper 20 will exert too great aforce against the wearer's stomach. In contrast, if the extensibility istoo low, the holding force acting about the wearer's waist will also betoo low. This may result in diaper 20 slipping down from the wearer'swaist, thereby rendering diaper 20 ineffective for its intended use.

Leg panel 202 a preferably has an extensibility which can vary fromabout 1 g/mm to about 30 g/mm or from about 3 g/mm to about 20 g/mm orfrom about 5 g/mm to about 15 g/mm. If the extensibility is too high,leg cuffs 32 will be under high tension, tending to cut into thewearer's thighs, leading to discomfort from excessive pressure of legcuff 32 against the thigh and to resulting red marks. If theextensibility is too low, leg cuffs 32 might not be tensionedsufficiently to maintain complete contact of leg cuff 32 completelyaround the wearer's thigh. This may result in leakage between leg cuff32 and the thigh.

Another form of an interior open area in side panel 73 to provide thebenefits of the present invention is shown in FIG. 6, wherein anelongated, narrow open area 256 is provided in side panel 73 b. Openarea 256 includes substantially parallel sides and terminates in roundedcorners to reduce stress concentrations and prevent tearing of sidepanel. The longitudinal centerline 206 b of open area 256 extendspreferably substantially perpendicular to longitudinal centerline 67 ofdiaper 20 and is preferably offset from the longitudinal centerline 206of side panel 73 b so that the waist panel 200 b has a greater effectivewidth than does the leg panel 202 b. Other forms of interior open areascan also be provided, and they preferably are so formed and positionedto result in a larger tensile force in waist panel 200 b than in legpanel 202 b when side panel 73 b is placed under tension by a tensileforce applied to side panel 73 b, such as during the time diaper 20 isbeing applied to a wearer and also when it is being worn.

In addition to interiorly-positioned open areas having the formillustrated in FIGS. 5 and 6, another way in which the relative levelsof tensile forces within the side panel in the waist direction and inthe leg-cuff direction can be controlled is by providing one or morecuts or slits extending through the side panel material. Referring toFIGS. 7 and 8, one or more rectilinear cuts or slits can be provided inthe interior portion of the respective side panels shown. In the FIG. 7embodiment, which shows side panel 73 c, there is only a single slit260, which extends in the direction of and defines the width of waistregion 262, and which therefore defines the division of tensile forcesbetween the waist region 262 of side panel 73 c and a leg region 263.Slit 260 is inclined relative to lateral centerline 66 of diaper 20,preferably at angle A (see FIGS. 3 and 5 and accompanying descriptionhereinabove), and preferably has a length which can vary from about0.125 in (about 3 mm). to about 2.5 in. (about 64 mm) or about 0.25 in.(about 6 mm) to about 2.0 in. (about 50 mm) or from about 0.5 in. (about13 mm) to about 1.5 in (about 38 mm).

FIG. 8 illustrates another embodiment of side panel 73 d of the presentinvention having more than one slit, for example, three generallyrectilinear slits 264, 266, and 268. Slit 264 can extend in a directionsubstantially perpendicular to longitudinal centerline 67 of diaper 20and serves to divide the tensile force applied to side panel 73 dbetween the waist region 267 and the leg region 269. Slit 266 can extendin the direction of and can define the width of waist region 267, andslit 268 can extend in the direction of and can define the width of legregion 269. The angular disposition of slits 266 and 268 can be withinthe ranges specified hereinabove for angles A and B, respectively, inconnection with the discussion of FIG. 3. The lengths of slits 264, 266,and 268 can vary from about 0.125 in. (about 3 mm) to about 2.5 in.(about 64 mm) or from about 0.25 in. (about 6 mm) to about 2.0 in.(about 51 mm) or from about 0.5 in. (about 13 mm) to about 1.5 in (about38 mm).

Another embodiment of side panel 73 e which also includes a plurality ofslits, is shown in FIG. 9, wherein slits 270 are each preferablycurvilinear, or arc-shaped, with the respective centers of arcs 270positioned inwardly of arcs 270 so that the open portions of arcs 270face toward longitudinal centerline 67 of diaper 20. Arcs 270 are sopositioned relative to each other to define a generally triangularpattern of arcs 270, to divide a lateral tensile force applied to sidepanel 73 e so that individual tensile forces are directed to waistregion 272 and leg region 274 of side panel 73 e. Arcs 270 can have thesame size radii or they can have differently-sized radii. In thatregard, arcs 270 have radii which can vary from about 1.0 in. (about 25mm) to about 20 in. (about 508 mm) or from about 2.0 in. (about 51 mm)to about 15 in. (about 38 mm) or from about 5 in. (about 127 mm) toabout 10 in. (about 254 mm).

The cuts and openings shown in FIGS. 4-9 operate asinteriorly-positioned stress relief or stress interruption areas, andthey preferably are so disposed as to cause the tensile forces appliedto the respective side panels to be divided between the waist region andthe leg region of the side panel, so that each of the diaper waistregions and the leg regions are under a tensile stress that serves tohold the diaper about the wearer's waist and about the wearer's thighswithout unduly large hoop stresses within the diaper structure thatcould operate to cause discomfort to the wearer or red marks on thewearer's skin.

The force-dividing effect of the interior cuts and openings in the sidepanels is illustrated diagrammatically in FIG. 10. As noted earlier,interiorly-positioned openings and cuts in the material from which theside panels are formed serve to reduce or prevent the transmission oftensile forces within the side panels along the same line as that of anapplied external tensile force. In that regard, the external tensileforce T is divided into a waist-directed force W and a leg-cuff-directedforce L. Because of the effect of the cuts and openings in reducing thetransmission of tensile forces within the side panel in a directionopposite to and aligned with the direction of the externally-appliedtensile force, the tensile forces within the side panel extend angularlyrelative to the externally-applied force. When resolved into theirrespective components, waist region force W has a longitudinal componentW_(L) that extends in the direction of the longitudinal axis 67 ofdiaper 20, and a transverse component W_(T) that extends in thedirection of the lateral centerline 66 of diaper 20. Similarly, legregion force L has a longitudinal component L_(L) that extends in thedirection of the longitudinal axis 67 of diaper 20, and a transversecomponent L_(T) that extends in the direction of the lateral centerline66 of diaper 20.

As the diaper 20 is applied to the wearer, each of the side panels isstretched laterally to place it under tension. When the diaper has beenplaced in position and secured, the diaper and its components are inequilibrium and W_(L)=L_(L) and W_(T)+L_(T)=T. As will be appreciated bythose skilled in the art, the division of tensile forces within the sidepanels can be varied to accommodate particular conditions. Accordingly,the sizes and orientations of interiorly-positioned openings and cutscan be varied to provide the desired results.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

While particular embodiments and/or individual features of the presentinvention have been illustrated and described, it would be obvious tothose skilled in the art that various other changes and modificationscan be made without departing from the spirit and scope of theinvention. Further, it should be apparent that all combinations of suchembodiments and features are possible and can result in preferredexecutions of the invention. Therefore, the appended claims are intendedto cover all such changes and modifications that are within the scope ofthis invention.

1. A disposable article configured to be worn over and about the lowertorso of a wearer, the article comprising: a) a containment assemblyhaving a first longitudinal edge and a second longitudinal edge opposedthereto, a first end edge and a second end edge opposed thereto, thefirst and the second longitudinal edges being configured to contact thelegs of the wearer, and the first and the second end edges beingstructured and configured to contact the waist of the wearer; and b) atleast one elastomeric side panel carried by the containment assembly andextending outwardly from the first longitudinal edge of the containmentassembly adjacent the first end edge of the containment assembly, the atleast one elastomeric side panel including an inner region having atleast one discontinuity for dividing a tensile force applied to the atleast one elastomeric side panel into a waist-directing force and aleg-directing force wherein the at least one discontinuity is surroundedby the inner region of the at least one elastomeric side panel.
 2. Thedisposable article of claim 1, wherein the at least one discontinuity isdefined by at least one cut line, wherein the at least one cut line isdisposed substantially parallel with a first lateral edge of the atleast one elastomeric side panel.
 3. The disposable article of claim 2,wherein the at least one cut line is rectilinear.
 4. The disposablearticle of claim 2, wherein the at least one cut line is curvilinear. 5.The disposable article of claim 2, further comprising a second cut lineand a third cut line.
 6. The disposable article of claim 5, wherein thesecond cut line extends substantially parallel to a lateral centerlineof the at least one elastomeric side panel, and the third cut lineextends substantially parallel to a second lateral edge of the at leastone elastomeric side panel.
 7. The disposable article of claim 1,wherein the waist region has a greater width than the leg region.
 8. Thedisposable article of claim 1, wherein the at least one elastomeric sidepanel further includes a waist region and a leg region separated by theat least one discontinuity, wherein the waist region is configured totransmit a waist-directing force, and the leg region is configured totransmit a leg-directing force, and wherein the waist region has anextensibility varying from about 5 g/mm to about 50 g/mm and the legregion has an extensibility varying from about 1 g/mm to about 30 g/mm.9. The disposable article of claim 1, wherein the waist-directing forcein the waist region of the at least one elastomeric side panel extendsat an angle ranging from about 0° to about 45° relative to a lateralcenterline of the disposable article, and wherein the leg-directingforce in the leg region of the at least one elastomeric side panelextends at an angle ranging from about 10° to about 35° relative to thelateral centerline of the disposable article.
 10. The disposable articleof claim 1, wherein the waist-directing force in the waist region of theat least one elastomeric side panel extends at an angle ranging fromabout 10° to about 15° relative to a lateral centerline of thedisposable article, and wherein the leg-directing force in the legregion of the at least one elastomeric side panel extends at an angleranging from about 20° to about 30° relative to the lateral centerlineof the disposable article.
 11. The disposable article of claim 1,wherein the at least one elastomeric side panel has an extensibilityranging from about 1 g/mm to about 50 g/mm.
 12. The disposable articleof claim 1, wherein the at least one elastomeric side panel is elasticand has an elasticity of at least about 5%.